Contents
Greenstar – 6721822579 (2021/01)
2
Contents
1 Explanation of symbols and safety instructions. . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 4
2 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 ZBR...-3A - Residential boiler for space heating
and loading of indirect fired DHW tanks . . . . . . . . . . . . . 6
2.2 ZWB...-3A - Residential combi boiler for space
heating and DHW generation . . . . . . . . . . . . . . . . . . . . . . 7
3 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Product dimensions and minimum clearances . . . . . . . . 9
3.7 Appliance layout heating boiler ZBR...-3A. . . . . . . . . . . 10
3.8 Appliance layout ZWB...-3A . . . . . . . . . . . . . . . . . . . . . . 12
3.9 Electrical wiring ZBR...-3A . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 Electrical wiring ZWB...-3A. . . . . . . . . . . . . . . . . . . . . . . 16
3.11 Technical data ZBR...-3A . . . . . . . . . . . . . . . . . . . . . . . . 18
3.12 Technical data ZWB...-3A . . . . . . . . . . . . . . . . . . . . . . . . 21
3.13 Condensate composition . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Compliance with standards and regulations . . . . . . . . . 23
4.2 Operating limits of the boiler . . . . . . . . . . . . . . . . . . . . . 23
4.3 Additional regulations for installations in the
Commonwealth of Massachusetts . . . . . . . . . . . . . . . . . 24
5 Examples of Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Multiple zones using zone valves with DHW. . . . . . . . . . 25
5.2 Multiple zones using circulators . . . . . . . . . . . . . . . . . . . 27
6 Notes on installation and operation . . . . . . . . . . . . . . . . . . . . . 29
6.1 Notes on installation and operation . . . . . . . . . . . . . . . . 29
6.1.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.2 Other important information . . . . . . . . . . . . . . . . . . . . . 30
6.1.3 Water Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2 Comparing the size of the integrated expansion
vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 Selecting an external expansion vessel (ZBR...-
3A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4 Selecting the installation location . . . . . . . . . . . . . . . . . 31
6.5 Pre-installing pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.6 Mounting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.7 Installing the low water cut off (LWCO) . . . . . . . . . . . . . 34
6.8 Connecting flue gas accessories . . . . . . . . . . . . . . . . . . 35
6.8.1 Installation of the exhaust and air intake system. . . . . . 36
6.8.2 Examples of approved horizontal and vertical
venting installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.8.3 Vent and combustion air pipe lengths . . . . . . . . . . . . . . 42
6.9 Testing gas and water connections for leaks . . . . . . . . . 43
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Low voltage electrical connections in the
Heatronic boiler control . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2.1 Open the Heatronic boiler control . . . . . . . . . . . . . . . . . 44
7.2.2 Connecting the BUS-system. . . . . . . . . . . . . . . . . . . . . . 44
7.2.3 Connecting the outdoor temperature sensor . . . . . . . . 45
7.2.4 Connecting the DHW tank temperature sensor
(only ZBR...-3A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2.5 Connecting additional accessories . . . . . . . . . . . . . . . . 45
7.3 Electrical connections in the junction box
(120 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3.1 Mounting rails for junction box. . . . . . . . . . . . . . . . . . . . 47
7.3.2 Connecting an external heating zone pump or
DHW recirculation pump . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3.3 DHW tank loading pump or 3-way valve with spring
return (only ZBR...-3A). . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3.4 Connecting mains power supply . . . . . . . . . . . . . . . . . . 48
7.4 Connecting the LWCO device. . . . . . . . . . . . . . . . . . . . . 49
8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Before operating the appliance . . . . . . . . . . . . . . . . . . . 51
8.2 Switching the appliance ON/OFF. . . . . . . . . . . . . . . . . . 51
8.3 Switch on heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.4 Programming the Bosch Room Controller. . . . . . . . . . . 52
8.5 After commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.6 ZBR...-3A appliances (heating boilers) with DHW
tank: Setting the DHW temperature. . . . . . . . . . . . . . . . 52
8.7 ZWB...-3A appliances (combi boilers):
Setting the DHW temperature . . . . . . . . . . . . . . . . . . . . 53
8.8 Setting manual summer mode . . . . . . . . . . . . . . . . . . . . 53
8.9 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.10 Activating the key pad lock. . . . . . . . . . . . . . . . . . . . . . . 54
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